Idler arm installation
 

ref; rebuild of 73.5 2.4 - I got the newer style idler arms (the ones with the bushings) and they don't want to slip on the shaft very easily. They get about half way on and then get tight. Is this normal? I can put a deep socket on and give them a couple of firm taps to seat them but is that OK?

Take a real close look at your idler shafts. The old style arms can tear the hell out of them. I've seen several shafts that have a step worn into them and at the step the material can be beaten proud of the normal diameter. These steps are on the bottom of the shafts and you may not see them unless you go looking for them.
It's not for nothing that the new arms have a softer, wider bearing surface.

Is it OK just to file the burr off of the step?